Single Piece Expansion Sealing Plug

ABSTRACT

A single piece expansion plug and method of using the same in connection with a tool is provided. The plug has an inner recess extending partially into a top of the plug, the inner recess defining a tapered inner wall. The plug is installed with a tool having a tapered end at a greater angle with respect to the taper inner wall. The tool presses against the tapered inner wall to expand the plug against a hole. The tool includes a pin that retracts against a spring to seat the plug in the hole to be sealed such that the pin contacts the plug prior to the tapered inner wall and tapered end coming into contact.

FIELD OF THE INVENTION

The following relates to sealing plugs for holes and passageways. Moreparticularly, the following relates to a single piece expansion sealingplug.

BACKGROUND OF THE INVENTION

There are numerous types of plugs available that seal holes. Oftentimes,holes are made in parts for the purposes of connecting other holestogether to create internal passageways for fluids. In some cases, holesare made to access internal components that later need to be sealed. Anumber of solutions are available in multi piece plugs such as ballexpansion plugs. These ball expansion plugs involve a cylindrical piecewith a cylindrical relief cut out from the inside thereof. A ball ispress fit into this cylindrical relief to hold the two together. Theassembly is placed in a hole that has a two step diameter such that oneend of the cylindrical piece inserts into the hole and stops where thediameter steps down. A hammer, such as a pneumatic hammer is then usedto further press the ball into the cylindrical piece and thereby expandthe cylindrical piece outwardly to seal the hole. While these are typesof plugs work very effectively, they suffer a downside in that twopieces are required to be machined and assembled. This adds expense andcomplexity. Further, the step down installation hole involves two stepsfor creation thereof.

Other types of expansion plugs are disclosed in US Pat. Pub. No.2015/0202754. This type of plug involves a hollow cylinder and aninternal tapered piece that is fit to the cylinder. A tool attaches tothe internal tapered piece and pulls that piece into the cylinder toexpand the cylinder against the hole. This style of plug provides anumber of benefits, but is still a two piece plug that may not besuitable for certain applications.

Although simple plugs that do not expand might be capable of beingforced into a hole to seal it, the problem is that as such a plug isforced in, it could scratch the sides of the hole and provide a leakagepathway, thus reducing the ability of such a plug to resist elevatedpressures.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a single pieceexpansion plug that is both cost effective and simple to install.

A further object is to provide a single piece expansion plug that sealsa tapered hole.

Still a further object is to provide a single piece expansion plug thatis capable of withstanding elevated pressures and resisting blow out.

Yet another object is to provide an installation tool and method ofinstalling a single piece expansion plug that is both reliable andrepeatable.

These and other objects are achieved by providing a single pieceexpansion plug and method of using the same in connection with a tool isprovided. The plug has an inner recess extending partially into a top ofthe plug, the inner recess defining a tapered inner wall. The plug isinstalled with a tool having a tapered end at a greater angle withrespect to the taper inner wall. The tool presses against the taperedinner wall to expand the plug against a hole. The tool includes a pinthat retracts against a spring to seat the plug in the hole to be sealedsuch that the pin contacts the plug prior to the tapered inner wall andtapered end coming into contact.

Other objects are achieved by providing a single piece expansion plugwith an external tapered wall and a recess in the top of the plug. Theexternal tapered wall at the recess is configured to expand outwardlyagainst an installation hole to seal said hole. The expansion isaccomplished through use of a tool with a spring loaded pin thatcontacts the plug to seat the plug in the hole and retracts to allow anouter tapered end part of the tool contact the plug at the recess toexpand the plug against the hole.

In one aspect a kit is provided for sealing a hole. The kit includes aplug and a tool. The plug includes a single piece unitary body with abottom and a top and a side wall disposed therebetween. The side wall isoutwardly tapered from the bottom towards the top at a first angle. Arecess is located in the top and extends partially into the body andterminates at a recess base between the top and bottom. An inner wall isdefined by the recess and tapers outwardly from the recess base towardsthe top at a second angle. The installation tool includes a tapered endsection located at a distal end of the installation tool, the taperedend section tapering inwardly at a third angle that is greater than thesecond angle. A pin is located in a channel extending into the tool fromthe distal end. The pin is configured to move along a central axis ofthe tool such that in an extended position, the pin extends beyond thedistal end.

The plug may include a protrusion extending from the recess thereof. Theprotrusion includes a central void therein, the protrusion and centralvoid are aligned along a central axis of the plug. The tool inclues acentral void at the distal end with a diameter such that the protrusionfits into the central void. In some cases the first, second and thirdangles are all different. In other aspects ribs are located on the sidewall between the top and the recess base.

In other aspects a plug is provided which includes a single pieceunitary body with a bottom and a top and a side wall disposedtherebetween. The side wall is outwardly tapered from the bottom towardsthe top at a first angle. A recess is located in the top and extendspartially into the body and terminates at a recess base between the topand bottom. An inner wall is defined by the recess and tapers outwardlyfrom the recess base towards the top at a second angle.

In certain aspects a central recess is located at a central axis of thesingle piece unitary body within the recess. In other cases, aprotrusion extends from the recess base and the central recess islocated within the protrusion. In other aspects, the body is symmetricalaround a central axis thereof. In other aspects a plurality of ribsextend around the circumference of the side wall and extending outwardlysuch that each one of the ribs is separated from the others of the ribs.In certain aspects two of the ribs are positioned on the sidewall at adistance from the top that is less than a distance between the top andthe recess base. In certain aspects, the second angle is at least 1.5times the first angle. In other aspects, the first angle is 1-7 degreesand the second angle is 5-15 degrees.

In other aspects, a method is provided for sealing a hole including thesteps of: providing a tapered hole; inserting a plug into the taperedhole, the plug having a single piece unitary body with a bottom and atop and a side wall disposed therebetween, a recess located in the topextends partially into the body, the recess defining an inner wall ofthe plug; aligning an installation tool with the tapered hole and theplug; moving the installation tool axially towards the hole such that anend section of the installation tool presses on the inner wall to expandthe plug outwardly towards the tapered hole.

In certain aspects, a pin is located in a central void of a distal endof the installation tool, an end of the pin configured to move along ancentral axis of the tool such that in an extended position, the pinextends beyond the distal end and said pin retracts towards the distalend as the end section of the installation tool expands the plugoutwardly. In other aspects, movement of the pin is resisted by a springof the installation tool and an installation force for the plug is atleast 50 times a total spring force measured at maximum displacement ofthe pin during installation of the plug.

In other aspects movement of the pin is resisted by a spring of theinstallation tool and a first force is at least twice a second force.The first force is exerted by the pin against the plug during the movingstep when the end section first makes contact with the inner wall; andthe second force is exerted by the pin against the plug at a maximumdisplacement of the pin.

In other aspects, movement of the pin is resisted by a spring of theinstallation tool having a spring rate measured as force/inch, whereinthe force in pounds of the spring rate is less than 10% of aninstallation force in pounds exerted against the plug.

In other aspects, a tool is provided for installing a plug which seals ahole. The tool includes a proximal end and a distal end, the proximalend being thicker than the distal end. A pin is located in an interiorchannel and aligned with a central axis of the tool. The interiorchannel extends to the distal end. The pin is connected to a spring. Thepin, in an extended position protrudes from the distal end at adistance. The pin is configured to retract within the channel withresistance from the spring. An an end section of the tool is located atthe distal end and has an inward taper in a direction from the proximaltowards the distal end. An inner diameter is located where the channeland distal end meet. The inner diameter is greater than a diameter ofthe pin such that a space exists between the the pin and the distal end.

In other aspects the channel includes female threads and the pin is heldin the channel by a threaded member with male threads accessible fromthe proximal end of said tool. In some aspects the male and femalethreads are held in a fixed position by a thread locking compound.

Other objects of the invention and its particular features andadvantages will become more apparent from consideration of the followingdrawings and accompanying detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a plug according to the presentinvention.

FIG. 2 is a side view of FIG. 1

FIG. 3 is top view of FIG. 1

FIG. 4 is bottom view of FIG. 1

FIG. 5 is a sectional view of FIG. 1

FIG. 6 shows the tool for installing the plug of FIG. 1

FIG. 7 shows an exploded view of the tool for installing the plug ofFIG. 1

FIG. 8 shows a sectional view of the tool and plug of FIG. 1.

FIGS. 9-16 show the process of installing the plug of FIG. 1

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings, wherein like reference numerals designatecorresponding structure throughout the views. The following examples arepresented to further illustrate and explain the present invention andshould not be taken as limiting in any regard.

The plug 2 includes bottom 4 and top 6 ends. As can be seen, the plug isunitary and made of a single piece. In one example, the plug might bemachined from a solid piece of metal. Other manufacturing techniques maybe used to create the plug for example stamping as well as sintering,casting or other manufacturing techniques that would be apparent tothose skilled in the art.

A side wall 10 extends between the bottom 4 and top 6 ends. The sidewall is tapered. In one aspect, the taper angle matches that of the holewhere the plug is to be installed. In one embodiment, the taper angle 24of the side wall 10 is 0.075 MM taper/MM. As can be seen, where the sidewall 10 and the bottom 4 meet, the edge 11 is rounded.

The top 6 includes a recess 8 therein. The recess defines an inner sidewall 14 that is tapered inwardly from the top 6 towards the recess base9. The taper angle 22 generally ranges from 5-15 degrees. In the exampleshown, the recess base is a flat ring shaped surface. Ribs 12 arelocated on the part of the side wall opposite the inner side wall 14. Asshown, three of these ribs are located between the top 6 and the recessbase 9 and one of the ribs is located between the recess base 9 and thebottom 4. Additional or fewer ribs can be used, depending on the sealingcharacteristics desired. However, in most implementations, there will beone or more ribs 12 located between the top 6 and the recess base 9,typically so that when expanded outwardly, the ribs are located onsection of the plug between the inner side wall 14 and the side wall 10that is primarily deformed radially outwards. The depth 28 of the recess8 is defined from the top 6 to the recess base 9. This depth 28 is inthe range of 15-45% of the height 26 of the insert. More particularly,the depth 28 is 20-40% of the height 26, or more particularly 25-35% oreven more particularly 28-33%.

Within the recess 8 a central recess 18 is located on a protrusion 16that extends from the recess base 9. The central recess 18 is locatedalong the central axis 20 of the plug 2. This central recess 18 is usedto contact the pin of the installation tool to help seat the insert withthe appropriate force prior to expansion.

Referring now to the tool 200, the proximal end 100 has a diameter 101and is configured to be held and manipulated by a press. For example,the tool 200 may be placed into a chuck that holds the tool, the chuckconnected to a drive motor which moves the tool to install the plug 2.The distal end 102 of the tool 200 has a diameter 103 that is smallerthan the proximal end 100. A channel in the tool has a stop 105 which isconfigured as a hollow threaded bolt with male threads 118. The hollowend holds the pin 104 and spring 107. The channel 106 of the end 102includes female threads 116 which correspond to the male threads 118. Inone aspect, the stop 105 includes a hex key end that enables the springtension to be adjusted. On the opposite end of the spring is a stop nut109 which threads into the end of the tool to adjust the distance whichthe pin extends from the end part 108. In most cases, a thread lockingcompound such as Loctite® or other suitable compound is used to hold thestop 105 relative to the channel 106 during the press installationoperations.

The diameter 180 of the pin 114 is less than the diameter 112 of thechannel at the distal end 102, this creates a space 181 between the pinand the distal end. During installation, the protrusion 16 whichcontains the central recess 18 on the plug 2 fits within this space toallow the distal end and the tapered end part 108 to contact the innerwall 14 and extend into the recess 8.

FIGS. 9-15 show an exemplary process of installing the plug 2 in a hole.First, a block 9000 is provided, typically with two passageways 900, 902that are to be connected. A tapered drill 904 creates a hole in theblock, which connects the two passageways 900, 902. A deburring device908 finishes the top of the hole and the plug 2 is placed therein. Thetaper 910 of the hole matches the taper 22 of the plug 2. The tool thenpresses on the plug 2 such that pin 114 contacts the central recess 18.The spring action of the pin 114 allows the pin to retract as the toolpresses the plug 2 into the appropriate location in the hole. As thetapered end of the end part 108 contacts the wall 14 of the plug 2, theplug is expanded outwards and the ribs are pressed into the hole in theblock. The spring force of the pin 114 provides enough force to placethe plug 2 in the appropriate position while avoiding excessivescratching of the hole. Such scratches could become leak pathways, whichis prevalent in many other non-expansion type plugs. The expansionaction of the plug as expanded by the tapered end of the tool reduces oreliminates the need to force the plug down into the tapered hole in theblock 9000 and instead, outward expansion is obtained to provideimproved sealing. The forces used to provide the appropriate downwardpressure as related to the overall installation force are thereforeimportant for reducing the scratch/drag marks on the hole whileproviding effective sealing. In one example of a 7 mm size plug (7.01 mmdiameter), the total downward installation force is 800 pounds forcewith the spring travel 1500 being 0.125 inches. The spring force whereend 108 first contacts the wall 14 is 3.0 pounds and defines the contacttravel of the spring. The total force upon the 0.125 inch travel is 11.0pounds. The spring rate is 56.0 pounds/inch. It is understood that theseare exemplary figures which may be adjusted, particularly depending onthe size and material of the plug and/or block. Further, the stop nut109 is positioned such that it does not contact the plug at the end ofthe installation stroke shown at FIG. 15. Particularly, distance 1400 isgreater than the height of the protrusion 16.

In most cases, the plug 2 is made from aluminum and the block 9000 fromsteel. In one embodiment, pounds/mm plug diameter is in the range of75-200 pounds/mm diameter, or more particularly 100-125 pounds/mmdiameter. The installation force/spring contact force may be in therange of 175-375 or more particularly 225-300 with the spring forcemeasured at first contact of the end 108 during installation. Theinstallation force/final spring force is in the range of 50-125 or moreparticularly 65-85 with the final spring force being when the spring isfully compressed as shown in FIG. 15. Particularly, the contact travelin the 7 mm plug is approximately 0.05357 inches such that the contacttravel is about 42% of the overall travel 1500. This contact travel 1400may be in the range of 30-50% of the overall travel 1500.

Although the invention has been described with reference to a particulararrangement of parts, features and the like, these are not intended toexhaust all possible arrangements or features, and indeed many othermodifications and variations will be ascertainable to those of skill inthe art.

What is claimed is:
 1. A kit for sealing a hole comprising: (a) a plugincluding: a single piece unitary body with a bottom and a top and aside wall disposed therebetween, the side wall outwardly tapered fromthe bottom towards the top at a first angle; a recess located in the topand extending partially into the body and terminating at a recess basebetween the top and bottom; an inner wall defined by the recess andtapered outwardly from the recess base towards the top at a secondangle; (b) an installation tool including: a tapered end section locatedat a distal end of the installation tool, the tapered end sectiontapering inwardly at a third angle that is greater than the secondangle; a pin located in a channel extending into the tool from thedistal end, the pin configured to move along a central axis of the toolsuch that in an extended position, the pin extends beyond the distalend.
 2. The kit of claim 1 further comprising: a protrusion extendingfrom the recess of the plug and including a central void therein, theprotrusion and central void aligned along a central axis of the plug;the central void of the distal end having a diameter such that saidprotrusion fits into the central void.
 3. The kit of claim 1 whereinsaid first, second and third angles are all different.
 4. The kit ofclaim 1 further comprising: a plurality of ribs located on the side wallat a location thereon between the top and the recess base.
 5. A plugcomprising: a single piece unitary body with a bottom and a top and aside wall disposed therebetween, the side wall outwardly tapered fromthe bottom towards the top at a first angle; a recess located in the topand extending partially into the body and terminating at a recess basebetween the top and bottom; an inner wall defined by the recess andtapered outwardly from the recess base towards the top at a secondangle.
 6. The plug of claim 5 further comprising: a central recesslocated at a central axis of the single piece unitary body within therecess.
 7. The plug of claim 6 further comprising: a protrusionextending from said recess base, wherein said central recess is locatedwithin said protrusion.
 8. The plug of claim 5 wherein said body issymmetrical around a central axis thereof.
 9. The plug of claim 5further comprising a plurality of ribs extending around thecircumference of the side wall and extending outwardly wherein each oneof said plurality of ribs is separated from the others of said pluralityof ribs.
 10. The plug of claim 9 wherein at least two of said pluralityof ribs are positioned on the sidewall at a distance from the top thatis less than a distance between the top and the recess base.
 11. Theplug of claim 5 wherein the second angle is at least 1.5 times the firstangle.
 12. The plug of claim 5 wherein the first angle is 1-7 degreesand the second angle is 5-15 degrees.
 13. A method of sealing a holecomprising: providing a tapered hole; inserting a plug into said taperedhole, said plug having a single piece unitary body with a bottom and atop and a side wall disposed therebetween, a recess located in the topextends partially into the body, the recess defining an inner wall ofthe plug; aligning an installation tool with the tapered hole and theplug; moving the installation tool axially towards the hole such that anend section of the installation tool presses on the inner wall to expandthe plug outwardly towards the tapered hole.
 14. The method of claim 13further comprising a pin located in a central void of a distal end ofthe installation tool, an end of the pin configured to move along ancentral axis of the tool such that in an extended position, the pinextends beyond the distal end and said pin retracts towards the distalend as the end section of the installation tool expands the plugoutwardly.
 15. The method of claim 14 wherein movement of the pin isresisted by a spring of the installation tool and an installation forcefor the plug is at least 50 times a total spring force measured atmaximum displacement of the pin during installation of the plug.
 16. Themethod of claim 14 wherein movement of the pin is resisted by a springof the installation tool and a first force is at least twice a secondforce; the first force exerted by the pin against the plug during themoving step when the end section first makes contact with the innerwall; the second force exerted by the pin against the plug at a maximumdisplacement of the pin.
 17. The method of claim 14 wherein movement ofthe pin is resisted by a spring of the installation tool having a springrate measured as force/inch, wherein the force in pounds of the springrate is less than 10% of an installation force in pounds exerted againstthe plug.
 18. A tool for installing a plug which seals a hole, the toolcomprising: a proximal end and a distal end, the proximal end beingthicker than the distal end; a pin located in an interior channelaligned with a central axis of the tool, the interior channel extendingto the distal end, said pin connected to a spring; said pin in anextended position protruding from the distal end at a distance, said pinconfigured to retract within the channel with resistance from thespring; an end section of the tool located at the distal end having aninward taper in a direction from the proximal towards the distal end; aninner diameter located where said channel and distal end meet, the innerdiameter greater than a diameter of said pin such that a space existsbetween the said pin and the distal end.
 19. The tool of claim 18wherein said channel includes female threads and the pin is held in thechannel by a threaded member with male threads accessible from theproximal end of said tool.
 20. The tool of claim 19 wherein said maleand female threads are held in a fixed position by a thread lockingcompound.